308864
Rev. F
First choice when
quality counts.
Related Manuals
Operator 308863. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 309091. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip 309055. . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board 308919. . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Kit 308920. . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 308961. . . . . . . . . . . . . . . . . . . . . .
Model 232624
8737A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
5.5 HORSEPOWER, GASOLINE POWERED
GMAX 5900 Convertible
Airless Paint Sprayer
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model Series Description
232624 A Sprayer, gas powered
232625 A Sprayer, gas powered, with RAC 5 tip,
gun and hose
232626 A Sprayer, gas powered, with electric mo-
tor kit
232629 A Same as 232626 except with ETL ap-
proval to CSA and UL standards
232680 A Sprayer, gas powered, with Lo-Boy
suction set kit
232681 A Sprayer, gas powered, with RAC 5 tip,
gun and hose and Lo-Boy suction set kit
232682 A Sprayer, gas powered, with Lo-Boy suc-
tion set kit and electric motor kit
240774 A Electric motor kit converts sprayer to
electric powered sprayer.
240775 A Same as 240774 except with ETL ap-
proval to CSA and UL standards
Table of Contents
Component Identification and Function 3. . . . . . . . . . . .
Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing and Connecting Rod 7. . . . . . . . . . .
Drive Housing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly/Rotor/Field/Shaft/Clutch/Pulley 9. .
ON/OFF Switch 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Repair 12. . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 14. . . . . . . . . . . . . . . . . . .
Parts
Basic Sprayer 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayer 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lo-Boy Suction Set Kit 22. . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
2 308864
Warnings and Cautions
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Fluid injection is a serious injury! If high pressure fluid pierces
your skin, the injury might look like “just a cut”. But it is a serious
wound! Get immediate medical attention.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Point gun away from yourself or anyone else.
Relieve pressure before checking or repairing any leak.
Relieve pressure when you turn off the sprayer or stop spraying.
Do not use components rated less than system Maximum
Working Pressure
Never allow children to use this unit. If you are injured using this
equipment, get immediate medical treatment.
Fire and explosion can occur when spraying or flushing flammable
fluid in an area where air circulation is poor and flammable vapors
can be ignited by an open flame or sparks.
To help prevent a fire and explosion:
Use outdoors or in an extremely well ventilated area.
Do not use 1,1,1–trichloroethane, methylene chloride, other
halogenated hydrocarbon solvents or fluids containing such
solvents in pressurized aluminum equipment. Such use could
result in a chemical reaction, with the possibility of explosion.
Remove, extinguish or unplug all ignition sources;
tape wall switch. Do not smoke in spray area.
Never fill fuel tank while the engine is running or hot.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of a grounded pail when triggering into pail.
Use only conductive airless paint hose.
Never run engine in inclosed area.
WARNING
3308864
Component Identification and Function
Fig. 1
203
204
202
U
W
A
B
F
K
202Main hose
203Whip end hose
204Contractor gun with RAC 5
DripLess tip guard and 517 size SwitchTip
M
L
N
Model 232624
C
D
E
G
H
J
P
R
S
T
V
8738A
X
Y
A Pressure Control Switch ON/OFF, enables/disables clutch function
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering carburetor
D Fuel Tank* Holds 0.95 gallons (3.6 liter) of 86 octane gasoline
E Muffler* Reduces noise of internal combustion
F Spark Plug Cable* Routes electrical current to spark plug
G Fuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor
H Choke* Enriches air/gasoline mixture for cold starting
J Throttle Lever* Adjusts engine speed for large or small orifice spray tips
K Engine Switch* Enables/disables engine operation
L Secondary Fluid Outlet Second hose and spray gun is connected here
M Pressure Control Controls clutch cycling to maintain fluid pressure
N Primary Fluid Outlet Hose and spray gun is connected here
P Engine* 5.5 HP gasoline engine
R Clutch Housing Transfers power from engine to drive assembly
S Drive Housing Transfers power from clutch to displacement pump
T Displacement Pump Provides fluid to be sprayed through spray gun
U Fluid Filter Filters fluid between source and spray gun
V Grounding Clamp and Wire Grounds sprayer system
W Pressure Drain Valve Relieves fluid pressure when open
X Cord Provides electric power from engine alienator to control and clutch
Y Clamp Locks down engine/motor and provides belt tension
* For more detailed explanations of these controls, refer to Honda engine manual; supplied
4 308864
Maintenance
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
are instructed to relieve pressure,
stop spraying,
check or service any system equipment,
or install or clean spray tip.
Pressure Relief Procedure
1. Lock gun safety latch.
2. Turn engine or electric motor ON/OFF switch to
OFF.
3. Unplug power supply cord (electric motor).
4. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
5. Rotate RAC 5 tip, if used, to reverse position.
6. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
7. Lock gun safety latch.
8. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
tip or hose obstruction.
CAUTION
For detailed engine maintenance and specifications,
refer to separate engine manual, supplied.
DAILY: Check engine oil level and fill as necessary.
Manual 308863.
DAILY: Check that V-belt (60) is centered on pulleys
and is not inverted. Replace if worn or damaged.
DAILY: Check and fill gas tank.
DAILY: Check hoses for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper opera-
tion.
AFTER THE FIRST 20 HOURS OF OPERATION
AND EACH 100 HOURS THEREAFTER: Change
engine oil.
DAILY: Keep TSL in packing nut to help lubricate
pump packings. One full squirt of TSL is usually
enough.
WEEKLY: Remove cover of air filter (C) and clean
element. Replace element, if necessary. If operating in
an unusually dusty environment, check filter daily and
replace it, if necessary.
Repack connecting rod (22) top needle bearing after
every pump change.
Replacement elements can be purchased from your
local HONDA dealer.
SPARK PLUG: Use only an BPR6ES (NGK) or
W20EPR–U (NIPPONDENSO) plug. Gap plug to
0.028 to 0.031 in. (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing plug.
5308864
Troubleshooting
WARNING
INJECTION HAZARD
To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from
moving parts, always follow Pressure Relief Procedure Warning, page 4, before checking, adjust-
ing, cleaning or shutting down sprayer.
Check everything in chart before disassembling sprayer.
PROBLEM
CAUSE SOLUTION
Engine won’t start Engine switch is OFF Turn engine switch on.
Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.
Engine oil level low Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable disconnected or
spark plug damaged
Connect spark plug cable or replace spark plug.
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or 4 times.
Clean or replace spark plug. Try to start engine.
Keep sprayer upright to avoid oil seepage.
Engine operates, but
Pressure control switch turned OFF Turn on.
displacement pump
doesn’t
Pressure setting too low Increase pressure.
Displacement pump outlet filter dirty Clean filter.
Tip or tip filter clogged Clean tip or tip filter.
Broken drive belt Replace belt.
Displacement pump rod seized by
dry paint
Service pump. See page 14.
Connecting rod worn or damaged Replace. See page 7.
Drive housing worn or damaged Replace. See page 8.
Electrical power not energizing clutch field Check wiring connections. See page 20.
Reference control board diagnostics. See page 13.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check for
power between clutch terminals on control board.
Remove black clutch wires from control board and
measure resistance across wires. At 70 F, the
resistance must be between 1.7
±0.2Ω; if not, re-
place pinion housing.
Have pressure control checked by authorized Gra-
co dealer.
Clutch worn or damaged Service. See page 9.
Pinion assembly worn or damaged Service. See page 9.
6 308864
PROBLEM CAUSE SOLUTION
Pump output low
Strainer (31) clogged Clean.
Piston ball (25) not seating Service piston ball check. Manual 308798.
Piston packings worn or damaged Replace packings. Manual 308798.
O-ring (227) in displacement pump is worn or
damaged
Replace o-ring. Manual 308798.
Intake valve ball not seating properly Clean and service. Manual 308798.
Engine speed is too low Increase throttle setting. See Manual 308863.
V–belt slipping Tighten V–belt with clamp (101). Adjust clamp
until it takes 15 lb of force to lock clamp down.
Clutch worn or damaged Replace. See page 9.
Pressure setting is too low Increase pressure. Manual 308863.
Fluid filter (318), tip filter or tip is clogged or
dirty
Clean filter. Manual 308863 or 309091.
Large pressure drop in hose with heavy
materials
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4
in. hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum perfor-
mance (50 ft minimum).
Excessive paint leakage into
throat packing nut
Throat packing nut is loose Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings worn or damaged Replace packings. Manual 308798.
Displacement rod worn or damaged Replace rod. Manual 308798.
Spitting from gun Air in fluid pump or hose Check for loose connections at pump intake
and tighten. Then prime pump. See Startup,
Manual 308863.
Tip partially clogged Clear.
Fluid supply is low or empty Refill and prime pump. See Startup, Manual
308863. Check fluid supply often to prevent
running pump dry.
Pump is difficult to prime Air leak Check all hose connections and tighten as
needed.
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking Shut off pump and relieve pressure. Disas-
semble and clean intake valve. Be sure ball
seat is not nicked or worn and that ball seats
well. Reassemble.
Worn packings Repack pump. Manual 308798.
Fluid is too thick Thin fluid according to supplier’s recommenda-
tions.
Engine speed is too high Decrease throttle setting before priming pump.
Manual 308863.
High engine speed at no
load
Misadjusted throttle setting. Reset engine throttle to 3600 – 3800 rpm at no
load
Worn engine governor Replace or service engine governor
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other
when new and may cause noise
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time
7308864
Bearing Housing and Connecting Rod
Removal
1.
Relieve pressure; page 4.
2. Stop sprayer at bottom of stroke to get crank (E) in
lowest position.To lower crank manually, remove
spark plug and carefully rotate crank by pulling
starter rope.
3. Fig. 3. Remove front cover (13). Unclip drain hose
(108) from pump. Unscrew pump suction tube
(107) from pump. Disconnect pump hose (47).
4. Push up retaining spring (18). Push pin (19) out
rear.
Fig. 2
7675B
19
18
5. Loosen locknut (20). Unscrew displacement
pump (21).
6. Remove four screws and lockwashers (44, 45).
7. Tap lower rear of bearing housing (17) with a
plastic mallet to loosen from drive housing (12).
Pull bearing housing and connecting rod assembly
(14) straight off drive housing.
8. Remove pail hanger (59) and install it on new
bearing housing.
9. Inspect crank (E) for excessive wear and replace
parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (B) in
bearing housing (17) with high-quality motor oil.
Liberally pack top roller bearing (C), lower bearing
(D) inside connecting rod assembly (14) with
bearing grease 114819.
2. Assemble connecting rod (14) and bearing
housing (17).
3. Clean mating surfaces of bearing and drive hous-
ings (17, 12).
4. Align connecting rod (14) with crank (E) and drive
housing locating pins (12b) with bearing housing
(17) holes. Push bearing housing onto drive hous-
ing or tap into place with plastic mallet.
CAUTION
Do not use bearing housing screws (44) to align or
seat bearing housing; this may cause bearing and
drive housing misalignment and result in premature
bearing wear.
5. Install screws and lockwashers (44, 45). Tighten
screws evenly to 25 ft-lb (34 Nm).
6. Install pump; page 14.
7. Fig. 3. Install remaining parts.
Fig. 3
17
12
45, 44
13
18
21
14
B
C
59
Pack with bearing grease 114819
Oil
108
107
106
3
2
1
1
2
3
20
19
47
8697A
12b
E
2
Torque to 25 ft-lb (34 Nm)
D
57
8 308864
Drive Housing
1.
Relieve pressure; page 4.
Removal
2. Fig. 4. Remove bearing housing. Do Removal of
Bearing Housing and Connecting Rod proce-
dure on page 7.
3. Remove two screws (41) and lockwashers (10).
4. Remove four screws (9) and lockwashers (10)
from pinion housing (8).
5. Lightly tap around drive housing (12) to loosen
drive housing. Pull drive housing straight off pinion
housing (8). Be prepared to support gear cluster
(7) which may also come out.
CAUTION
Do not drop gear cluster (7) when removing drive
housing (12). Gear cluster is easily damaged. Gear
may stay engaged in drive housing or pinion housing.
Installation
1. Liberally apply bearing grease (supplied with re-
placement gear cluster) to gear cluster (18) and to
areas called out by note 2. Use full 0.68 pint (0.32
liter) of grease.
2. Place bronze colored washer (12g) on shaft pro-
truding from large shaft of drive housing (12).
Note: If replacing a washer with pin holes with a
washer without pin holes, remove guide pins from
housing. Place silver colored washer (12h) on pin-
ion housing. Assemble washers (15) and (16) onto
gear (7). Align gears and push new drive housing
straight onto pinion housing and locating pins (A).
3. Install four screws (9) and lockwashers (10) to
pinion housing (8) and drive housing (12).
4. Install two screws (41) and lockwashers (10) to
drive housing (12).
5. Fig. 4. Install bearing housing. Do 1. through 6. of
Bearing Housing and Connecting Rod proce-
dure on page 7.
9
10
12h
12g
41
10
12
8
A
7
A
Fig. 4
2
2
Apply remaining grease to these areas
1
Torque to 200 in-lb
1
1
15
16
15
TI0178B
9308864
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Removal
If pinion assembly (8) is not removed from clutch
housing (3), do 1. through 4. Otherwise, do 1 and then
start at 5.
1.
Relieve pressure; page 4.
2. Disconnect field cable (X) from pressure control.
Fig. 5
X
8739A
Bottom View
3. Fig. 6. Remove five screws (5) and lockwashers
(6) and pinion assembly (8).
5
6
5
6
Fig. 6
8740A
8
4. Fig. 7. Place pinion assembly (8) on bench with
rotor side up.
5. Remove four screws (39) and lockwashers (6).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
Fig. 7
E
39
6
8701A
6. Fig. 8. Remove retaining ring (Z).
7. Tap pinion shaft (A) out with plastic mallet.
Fig. 8
Z
A
8703A
8. Fig. 10. Remove drive belt shield (74) and
belt (68).
9. Hold pulley (2) and remove four screws (3a) and
washers (3h) from hub (3d). Remove armature
(3g) and spacer (3f).
10. Remove set screw (112a) from bushing (112).
Remove three bolts (112b) and three washers
(112c). Use bolts to remove pulley from bushing.
Remove pulley and key (1).
11. Remove three screws (27) from beneath mounting
plate (D).
12. Lift off clutch housing (3).
13. Remove retaining ring (3b). Pull jack shaft assem-
bly (3c) out.
10 308864
Pinion Assembly/Rotor/Shaft/Clutch/Pulley
Installation
1. Fig. 10. Install jack shaft assembly (3c). Install
retaining ring (3b).
2. Fig. 9. Lay two stacks of two dimes on smooth
bench surface.
3. Lay armature (4a) on two stacks of dimes.
4. Press center of clutch down on bench surface.
Fig. 9
4a
8705A
0.12 ±.01 in. (3.0 ±.25 mm)
5. Place spacer (3f) and armature (3d, 3g) on jack
shaft assembly.
6. Install three screws (27) through mounting plate
(D) and into clutch housing (3).
7. Insta
to
ll key (1) in bushing (112). Apply Locktite
to three bolts (112). Install bushing in pulley (2)
with three bolts (112b). Install set screw (112a) in
bushing. End of jackshaft (3c) must be 0.090 in.
below flush with end of bushing.
8. Hold pulley (2) and install four screws (3a) and
washers (3h) in hub (3d). Torque to 125 in-lb
(14 Nm).
9. Install drive belt shield (74).
10. Push drive housing (12) and pinion housing (8)
assembly onto clutch housing (3). Tap lightly on
front of bearing housing (17) with a plastic mallet
to push drive housing and pinion housing assem-
bly onto clutch housing.
11. Install five screws (5) and lockwashers (6).
12. Fig. 8. Tap pinion shaft (A) in with plastic mallet.
13. Install retaining ring (Z).
14. Fig. 7. Place pinion assembly on bench with rotor
side up.
15. Apply locktite to screws. Install four screws (39)
and lockwashers (6). Alternately torque screws to
125 in-lb until rotor is secure.
16. Install pinion assembly with five screws (5) and
lockwashers (6).
17. Fig. 5. Connect field cable (X) to pressure control.
Fig. 10
3h
3a
3g
8741A
3e
3b
1
3c
74
71
112a
68
112
27
D
3f
112b
2
3d
11308864
On/Off Switch
Removal
1.
Relieve pressure; page 4.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect two wires (A) from ON/OFF
switch (309).
4. Press in on two retaining tabs on each side of
ON/OFF switch (309) and remove.
Installation
1. Install new ON/OFF switch (309) so tabs of switch
snap into place on inside of pressure control
housing.
2. Connect two wires (A) to ON/OFF switch.
3. Install pressure control cover (322) with five
screws (307).
Fig. 11
8711A
322
307
A309
302
303
E
D
313
310
318z
318aa
318a
1
Locate switch terminals as shown
1
315 319
301
12 308864
Pressure Control
Control Board
Removal
1.
Relieve pressure; page 4.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Fig. 18. Disconnect at control board (302):
Four clutch leads: two violet and two black.
Lead (D) from potentiometer.
Lead (E) from transducer.
Two red leads (A) to ON/OFF switch (80).
4. Remove five screws (303), green ground wire and
circuit board (302).
Installation
1. Fig. 11. Install control board (302) and green
ground wire with five screws (303).
2. Connect to control board (302):
Two red leads (A) to ON/OFF switch (309).
Lead (E) to transducer.
Lead (D) to potentiometer.
Four clutch leads: two violet and two black.
3. Install cover (322) with five screws (307).
Pressure Control Transducer
Removal
1.
Relieve pressure; page 4.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (E) from control board (302).
4. Remove three screws (319) and fluid filter (318)
from control plate (301). Carefully pull transducer
connector through rubber grommet (315).
5. Remove pressure control transducer (318z) and
packing o-ring (318aa) from filter housing (318a).
Installation
1. Fig. 11. Install packing o-ring (318aa) and pressure
control transducer (318z) in filter housing (318a).
Torque to 30–35 ft-lb.
2. Carefully feed transducer connector through
rubber grommet (315). Install fluid filter (318) on
control plate (301) with three screws (319).
3. Connect lead (E) to control board (302).
4. Install cover (322) with five screws (307).
Pressure Adjust Potentiometer
Removal
1.
Relieve pressure; page 4.
2. Fig. 11. Remove five screws (307) and
cover (322).
3. Disconnect lead (D) from control board (302).
4. Loosen set screws on potentiometer knob (313)
and remove knob, shaft nut, lockwasher (310) and
pressure adjust potentiometer (310).
5. Remove seal (311) from potentiometer (310).
Installation
1. Install seal (311) on potentiometer (310).
2. Fig. 11. Install pressure adjust potentiometer (310),
shaft nut, lockwasher (310) and potentiometer
knob (313).
a. Turn potentiometer shaft (310) clockwise to
internal stop. Assemble potentiometer knob
(313) to strike pin on plate (312).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
3. Connect lead (D) to control board (302).
4. Install cover (322) with five screws (307).
13308864
Pressure Control
Control Board Diagnostics
1. Fig. 11. Remove five screws (307) and
cover (322).
2. Start sprayer.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
LED
BLINKS
SPRAYER OPERATION INDICATES WHAT TO DO
Two times
repeatedly
Sprayer shuts down and LED contin-
ues to blink two times repeatedly
Run away pressure.
Pressure greater than
4500 psi (310 bar, 31
MPa).
1. Check pressure transducer con-
nection at control board
2. Replace pressure transducer
3. Replace control board
Three
times re-
peatedly
Sprayer shuts down and LED contin-
ues to blink three times repeatedly
Pressure transducer is
faulty or missing
1. Check pressure transducer con-
nection at control board
2. Replace pressure transducer
3. Replace control board
Four times
repeatedly
Sprayer shuts down and LED contin-
ues to blink four times repeatedly
Generator voltage is
low
1. Increase engine throttle
2. Check wiring connections
3. Service Honda engine alternator
Five times
repeatedly
Sprayer shuts down and LED contin-
ues to blink five times repeatedly
High clutch current 1. Check clutch 5-pin bulkhead con-
nector. Clean contacts.
2. Measure 1.7 ±0.2Ω across clutch
field at 70F
3. Replace clutch field assembly
Six times
repeatedly
Sprayer shuts down and LED contin-
ues to blink six times repeatedly
High clutch temperature 1. If clutch is new, let sprayer cool
down and then restart
2. Inspect clutch. Replace clutch if
there is excessive wear.
3. Remove pump pin, separate pin-
ion housing from clutch housing.
Rotate rotor clockwise to check
for excessive drag.
14 308864
Displacement Pump
Removal
1. Flush pump.
2.
Relieve pressure; page 4.
3. Fig. 12. Cycle pump with piston rod (222) in its
lowest position.
4. Fig. 12. Remove suction tube (107) and hose (47).
Fig. 12
7672B
222
47
107
5. Fig. 13. Use screwdriver: push retaining spring up
and push out pin (19).
Fig. 13
7675B
19
6. Fig. 14. Loosen jam nut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
Fig. 14
7673B
Repair
See manual 308798 for pump repair instructions.
Installation
WARNING
If pin works loose, parts could break off due to
force of pumping action. Parts could project
through the air and result in serious injury or prop-
erty damage. Make sure pin and retaining spring
are properly installed.
CAUTION
If the pump jam nut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure jamnut is properly tightened.
1. Fig. 15. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
Fig. 15
7676B
1.5 in.
2. Fig. 13. Push pin (19) into hole. And push retaining
spring into groove all the way around connecting
rod.
3. Fig. 16. Screw jam nut down onto pump until
stops. Screw pump up into bearing housing until it
is stopped by jam nut. Back off pump and jam nut
to align pump outlet to back. Tighten jam nut by
hand, then tap 1/8 to 1/4 turn with a 20 oz (maxi-
mum) hammer to approximately 75" 5 ft–lb (102
Nm).
Fig. 16
7673B
4. Fig. 17. Fill packing nut with Graco TSL, through
one of the slits, until fluid flows onto the top of
seal.
Fig. 17
7677B
15308864
Notes
16 308864
Parts – Basic Sprayer
DETAIL A
1
2
See exploded view on page 18
See parts in manual 308798
See Engine Detail on page 17
3
4
See parts on page 19
Model 232624, Series A
43
8742B
7
8
14
13
45
17
12
1
1
2
18
20
106
107
104
21
56
108
47
59
61
105
19
57
42
4
39
6
4
60
58
108(Ref)
9
10
86
47(Ref)
51
52
50
49
112a
71
74
112b68
65
3
15
16
5
6
2112
48
10
41
109
122
27
44
76
72
101
2526
87
82
88
46
62
90
8739A
5
See parts on page 21
5
62
63
64
81
75
76 Ref
83
102
Bottom View
103
1
12h
12g
8(Ref)
79
40
79
117
11
6
6
Label
42(Ref)
131
132
3
55
17308864
Parts – Basic Sprayer
Ref.
No. Part No. Description Qty.
Ref.
No. Part No. Description Qty.
1 183401 KEY, parallel 1
2 193548 PULLEY 1
3 241306 CLUTCH HOUSING ASSY 1
4 193553 ROTOR, clutch, 5 in. 1
5 100644 CAPSCREW, sckt hd,, 1/4–20 x 3/4 in. 4
6 105510 LOCKWASHER, spring, 1/4 in. 11
7 241440 GEAR, combination 1
8 241112 PINION ASSEMBLY; Parts, page 18 1
9 101864 CAPSCREW, socket head, 4
1/4–20 x 3/4 in.
10 104008 WASHER, lock, spring 4
11 194125 LABEL, danger 1
12 241011 DRIVE HOUSING 1
13 241308 COVER, HOUSING, DRIVE 1
14 241012 CONNECTING ROD KIT 1
15 114672 WASHER, thrust 2
16 114673 WASHER 1
17 241015 BEARING HOUSING 1
18 183169 SPRING, retaining 1
19 183210 PIN, straight, 3/8 x1/8 in. 1
20 193031 NUT, retaining 1
21 240291 PUMP, displacement; 1
Parts, Manual 308798
25 114425 BUSHING, strain relief 1
26 114794 CORD, power, convertible 1
27 112395 SCREW, 3/8–16 x 3/4 in. 3
39 101682 SCREW, cap, sch 4
40 237686 GROUNDING CLAMP & WIRE 1
41 114686 SCREW, cap, sch 2
42 PRESSURE CONTROL 1
Parts, page 19
43 112798 SCREW, thread forming 1
44 114666 CAPSCREW, socket head, 4
45 106115 LOCKWASHER, spring, 3/8 in. 4
46 155699 ELBOW, street 1
47 222516 FLUID HOSE, 3/8 in. ID, 3/8 npt 1
couplings, 2.5 ft long, spring guards 1
48 193682 CAP, end; 2
49 154636 WASHER, 5/8 in. 2
50 101242 RING, retaining 2
51 104811 HUBCAP 2
52 179811 WHEEL, semi–pneumatic 2
56 114818 SCREW, self–tap 4
57 112746 LOCKNUT, 5/16–18 2
58 240131 PLUG, packless 1
59 192719 HANGER, pail 1
60 164672 ADAPTER 2
61 162485 NIPPLE, 3/8–18 npsm(m) x 1/4 npt(m) 1
62 240712 FRAME, cart 1
63 110243 RING, retaining 2
64 183350 WASHER 2
65 241003 GUARD, back 1
68 193547 BELT, 4V 1
71 111801 SCREW, cap, flng hd 4
72 114827 SPACER, hex 2
74 194099 GUARD, belt front 1
75 191084 SLEEVE, cart 2
76 239998 CART HANDLE 1
79 114810 EXTRUSION, trim 2
81 112827 BUTTON, snap 2
82 114809 BUSHING, strain relief 1
83 108795 SCREW, cap, sch 4
86 110838 LOCKNUT, w/nylon insert, 5/16–18 4
87 114391 SCREW, grounding 1
88 114687 CLIP, retainer 1
90 114806 EXTRUSION, gasket 1
101 241935 LATCH, adjustable 1
102 110885 SCREW, mach, pnhd, thrd forming 2
103 108947 NUT, square 2
104 187147 STRAINER 1
105 241718 .DEFLECTOR 1
106 194194 CLIP, spring 1
107 193097 TUBE, intake 1
108 194178 HOSE, coupled 1
109 110249 ADAPTER, male elbow, 90 1
111 206994 THROAT SEAL LIQUID, 1
8 oz (0.27 liter) (not shown)
117 114271 STRAP, retaining 1
122 114984 SCREW, tapping, pnhd, #10 x 1/2 in. 2
131 290228 LABEL, caution 1
132 ENGINE ASSY See Engine Detail 1
A 183401 KEY, parallel 1
B 193548 PULLEY 1
C 110996 NUT, flng hd, hex 8
D 114653 SCREW, cap, flng hd 4
E 112406 CAPSCREW, hex hd 2
F 194198 GUARD, lower engine 1
G 194087 HANDLE, slide 1
H 114530 ENGINE, 5.5 HP 1
J 194126 LABEL, warning 1
K 114805 JACK, 1/4, motor 1
L 194181 BOX, junction, engine 1
M 114816 NUT, hex 1
N 114813 SCREW, mach, hex washer hd 1
P 109099 BUSHING, snap 1
R 112586 SCREW, cap, hex hd, flanged 2
S 241313 PLATE, mount motor 1
T 194130 BRACKET, clamp 1
U 114959 BUSHING, 3/4 in. (3 bolts, 3 washers) 2
V 194414 BRACKET, J-box 1
W 194925 BRACKET, tension 1
X 192014 PLATE, indicator 1
Y 113084 RIVET, blind (not shown) 2
Z 111800 SCREW, cap, flanged hd 2
V
G
B
R
D
C
C
T
Z
S
F
E
M
8743A
A
U
W
LK
P
N
Engine Detail
YX
J
H
Replacement Danger and Warning labels, tags and
cards are available at no cost.
TI0177B
8d
8e
8b
8
12
12h
12g
9 (Ref.)
10 (Ref.)
7(Ref.)
9 (Ref.)
10 (Ref.)
15 (Ref)
16 (Ref)
18 308864
Parts List & Drawing – Pinion Assembly
Ref No. 8 and 12
Ref No. 8: Pinion Housing Assembly 241112 Ref No. 12: Drive Housing Assembly 241011
Ref
No. Part No. Description Qty
Ref
No. Part No. Description Qty
8 PINION HOUSING 1
8b 105489 PIN 2
8d* 193358 PINION SHAFT 1
8e* 112770 RETAINING RING, large 1
*Must be ordered separately
12 HOUSING, drive 1
12g* 194173 WASHER 1
12h* 194172 WASHER 1
*Must be ordered separately
19308864
Parts Drawing – Sprayer
307
322
305
310
311
306
315
318z
318aa
303
302
309
308
312
310
313
314
304
305
301
307
304
318c
318a
318b
318d
318a
318f
8716A
Ref No. 42
Pressure Control Assembly
318k
318j
318l
318n
318m
318h
318g
320
319
323
20 308864
Parts List – Sprayer
Models 232624
REF
NO. PART NO. DESCRIPTION QTY
REF
NO. PART NO. DESCRIPTION QTY
301 193653 PLATE, control 1
302 241093 BOARD, PC 1
303 111839 SCREW, mch pan, 6–32 x 1/2 in. 5
304 240776 HARNESS, wiring. 1
305 193497 GASKET, control 2
306 193652 HOUSING, control box 1
307 114631 SCREW, mch, pan hd 10
308 193052 PLATE, instruction 1
309 114277 SWITCH, rocker, (spst) 1
310 241443 POTENTIOMETER, pressure control 1
311 193657 GASKET, potentiometer 1
312 193654 PLATE, instruction 1
313 114273 KNOB, potentiometer 1
314 193072 LABEL, control 1
315 114629 GROMMET, transducer 1
318 FILTER, fluid 1
318a 193651 HOUSING, filter 1
318b 104361 O-RING 1
318c 186075 SUPPORT, filter 1
318d 167025 STRAINER, mesh, 60 1
318e 171941 SPRING, compression 1
318f 192706 BOWL, filter 1
318g 193710* SEAL, valve 1
318h 193709* SEAT, valve 1
318j 194102* HANDLE, valve 1
318k 114688* NUT, cap, hex hd 1
318l 114708* SPRING, compression 1
318m 114797* GASKET 1
318n 245103* VALVE 1
318z 240314 TRANSDUCER, pressure control 1
includes 318aa
318aa111457 O-RING 1
319 110997 SCREW, flange, hex 3
320 114532 TIE, wire, twist 1
321
189246 LABEL, warning 1
322 241444 COVER, pressure control 1
323 193684 LABEL, identification 1
* Drain valve replacement kit 245103 available; includes
318g through 318n
Replacement warning labels may be ordered free of charge
Fig. 18
8714A
Green
Violet
Pressure
transducer
Potentiometer
Red
Black
Pressure Control Wiring Diagram
Red
309
(Ref)
304
(Ref)
318z
(Ref)
310
(Ref)
302
(Ref)
D
E
A
318aa
(Ref)
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